US8937382B2 - Secondary device integration into coreless microelectronic device packages - Google Patents

Secondary device integration into coreless microelectronic device packages Download PDF

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Publication number
US8937382B2
US8937382B2 US13/169,162 US201113169162A US8937382B2 US 8937382 B2 US8937382 B2 US 8937382B2 US 201113169162 A US201113169162 A US 201113169162A US 8937382 B2 US8937382 B2 US 8937382B2
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Prior art keywords
microelectronic device
package
microelectronic
layer
secondary device
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US13/169,162
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US20120326271A1 (en
Inventor
Weng Hong Teh
John S. Guzek
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Intel Corp
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Intel Corp
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Priority to US13/169,162 priority Critical patent/US8937382B2/en
Assigned to INTEL CORPORATION reassignment INTEL CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GUZEK, JOHN S., TEH, Weng Hong
Priority to TW101119764A priority patent/TWI489917B/zh
Priority to PCT/US2012/043945 priority patent/WO2013003257A2/en
Priority to CN201280032156.7A priority patent/CN103620767B/zh
Priority to GB1321492.9A priority patent/GB2505802B/en
Priority to DE112012002654.3T priority patent/DE112012002654B4/de
Priority to JP2014517243A priority patent/JP5866441B2/ja
Priority to SG2013084900A priority patent/SG194999A1/en
Priority to DE112012007316.9T priority patent/DE112012007316B3/de
Publication of US20120326271A1 publication Critical patent/US20120326271A1/en
Priority to US14/566,198 priority patent/US9686870B2/en
Publication of US8937382B2 publication Critical patent/US8937382B2/en
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    • H01L21/02Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/04Manufacture or treatment of semiconductor devices or of parts thereof the devices having potential barriers, e.g. a PN junction, depletion layer or carrier concentration layer
    • H01L21/50Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
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    • H01L21/561Batch processing
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    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/30Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/32Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
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    • H01L23/3121Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed a substrate forming part of the encapsulation
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    • H01L2224/82001Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected by forming build-up interconnects at chip-level, e.g. for high density interconnects [HDI] involving a temporary auxiliary member not forming part of the bonding apparatus
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    • H01L2224/922Connecting different surfaces of the semiconductor or solid-state body with connectors of different types
    • H01L2224/9222Sequential connecting processes
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T29/49117Conductor or circuit manufacturing
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T29/49117Conductor or circuit manufacturing
    • Y10T29/49124On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/4913Assembling to base an electrical component, e.g., capacitor, etc.

Definitions

  • Embodiments of the present description relate generally to the field of microelectronic device package designs and, more particularly, to microelectronic device packages having bumpless build-up layer (BBUL) designs.
  • BBUL bumpless build-up layer
  • FIGS. 1-13 illustrate side cross-sectional views of a process of forming a bumpless build-up layer coreless (BBUL-C) microelectronic package with surface mounted device-side secondary devices, according to one embodiment of the present description.
  • BBUL-C bumpless build-up layer coreless
  • FIGS. 14-25 illustrate side cross-sectional views of a process of forming a bumpless build-up layer coreless (BBUL-C) microelectronic package with embedded device-side secondary devices, according to another embodiment of the present description.
  • BBUL-C bumpless build-up layer coreless
  • FIGS. 26-37 illustrate side cross-sectional views of a process of forming a bumpless build-up layer coreless (BBUL-C) microelectronic package with embedded device-side secondary devices, according to still another embodiment of the present description.
  • BBUL-C bumpless build-up layer coreless
  • Embodiments of the present description relate to the field of fabricating microelectronic device packages and, more particularly, to microelectronic device packages having bumpless build-up layer (BBUL) designs, wherein at least one secondary device, such as a capacitor, a micro electro-mechanical device (such as an accelerometer, radio frequency switches, and the like), a GPS device, a passive device, and the like, is disposed within the thickness (i.e. the z-direction or z-height) of the microelectronic device of the microelectronic device package.
  • BBUL bumpless build-up layer
  • openings or cavity structures may be created using relatively thick dielectric materials, such as photo definable photoresist materials, wherein microelectronic devices and components may be mounted therein.
  • relatively thick dielectric material cavities may enable packaging architectures that can allow surface mounting or embedding a variety of device side secondary devices without sacrificing z-height (i.e. thickness) constraints.
  • embodiments of the present description may allow for microelectronic device back surfaces being above the device side secondary devices, such that heat sinks may directly contact the microelectronic device back surfaces, or such that additional devices (e.g. memory, logic, etc) may be attached with through silicon vias to the microelectronic device back surfaces.
  • FIGS. 1-13 illustrate cross-sectional views of an embodiment of a process of forming a bumpless build-up layer coreless (BBUL-C) microelectronic package with surface mounted device-side secondary devices.
  • a carrier 100 may be provided.
  • the carrier 100 illustrated may be a copper laminated substrate comprising an adhesion material 106 disposed between two opposing copper release layers (i.e. a first copper release layer 104 and a second copper release layer 104 ′) with a two opposing copper layers (i.e. a first copper layer 102 and a second copper layer 102 ′) abutting their respective copper release layers (i.e.
  • the adhesion material 106 may be any appropriate material, including but not limited to an epoxy material. It is understood that although the layers laminated with the adhesion material 106 are specifically identified as copper layers (i.e. the copper layers and the copper release layers), the present description is not so limited, as the layers may be made of any appropriate material.
  • a first sacrificial material layer 110 such as a photoresist material
  • a second sacrificial material layer 110 ′ such as a photoresist material
  • a first protective layer 120 such as a metal foil (for example, copper foil)
  • a second protective layer 120 ′ such as a metal foil (for example, copper foil)
  • a metal foil for example, copper foil
  • the first sacrificial material layer 110 and the second sacrificial material layer 110 ′ may be formed by any technique known in the art, including but not limited to spin coating, dry photofilm lamination, and chemical vapor deposition.
  • the first protective layer 120 and the second protective layer 120 ′ may be formed by any technique known in the art, including but not limited to deposition and foil lamination.
  • the first and second sacrificial material layer 110 and the second sacrificial material layer 110 ′ may be deposited to thickness of between about 300 ⁇ m and 600 ⁇ m.
  • secondary device pads may be formed on the protective layers.
  • a first secondary device pad 124 a and a second secondary device pad 124 b may be formed on the first protective layer 120
  • a third secondary device pad 124 a ′ and a fourth secondary device pad 124 b ′ may be formed on the second protective layer 120 ′.
  • Metallization layers i.e. elements 122 a , 122 b , 122 a ′, and 122 b ′ may be disposed between their respective protective layers (i.e. elements 120 and 120 ′) and their respective secondary device pads (e.g. elements 124 a , 124 b , 124 a ′, and 124 b ′).
  • PoP package-on-package
  • first package-on-package pad 128 a and a second package-on-package pad 128 b may also be formed on the first protective layer 120
  • a third package-on-package pad 128 a ′ and a fourth package-on-package pad 128 b ′ may be formed on the second protective layer 120 ′.
  • Metallization layers i.e. elements 126 a , 126 b , 126 a ′, and 126 b ′ may also be disposed between their respective protective layers (e.g. elements 120 and 120 ′) and their respective package-on-package pad (e.g. elements 128 a , 128 b , 128 a ′, and 128 b ′).
  • the package-on-package pads may be used to form connections between microelectronic device packages in the z-direction for stacking (e.g. referred to as 3D stacking), without the need for through silicon vias.
  • the secondary device pads and the package-on-package pads may be formed by any technique known in the art, including deposition, photolithography, and etching.
  • an opening 132 may be formed through the first protective layer 120 to expose a portion of the first sacrificial material layer 110 , and an opening 132 ′ may be formed simultaneously in second protective layer 120 ′ to expose a portion of the second sacrificial material layer 110 ′.
  • the first protective layer opening 132 and the second protective layer opening 132 ′ may be formed by any technique known in the art, including but not limited to photolithographic patterning and etching. It is understood that the first sacrificial material layer 110 and the second sacrificial material layer 110 ′ may act as an etch stop during the formation of the first protective layer opening 132 and the second protective layer opening 132 ′.
  • an opening 134 may be formed, using the first protective layer 120 as a mask, through the first sacrificial material layer 110 to expose a portion of the carrier first surface 108 .
  • An opening 134 ′ may be formed simultaneously, using the second protective layer as a mask, through the second sacrificial material layer 110 ′ to expose a portion of the carrier second surface 108 ′.
  • the first sacrificial material layer opening 134 and the second sacrificial material layer opening 134 ′ may be formed by any technique known in the art, including but not limited to photolithographic processes and wet or dry etching, wherein the first copper layer 102 and the second copper layer 102 ′ may act as etch stops.
  • a first microelectronic device 142 may be attached by a back surface 150 thereof with an adhesive material 144 to the carrier first surface 108 within the first sacrificial material layer opening 134 .
  • the first microelectronic device 142 may have at least one contact land (shown as elements 146 a and 146 b ) on an active surface 148 thereof.
  • a second microelectronic device 142 ′ may be attached by a back surface 150 ′ with an adhesive material 144 ′ to the carrier second surface 108 ′ within the second sacrificial material layer opening 134 ′.
  • the second microelectronic device 142 ′ may have at least one contact land (shown as elements 146 a ′ and 146 b ′) on an active surface 148 ′ thereof.
  • the first microelectronic device 142 and the second microelectronic device 142 ′ may be any desired device, including but not limited to a microprocessor (single or multi-core), a memory device, a chipset, a graphics device, an application specific integrated circuit, or the like.
  • the adhesive material 144 and 144 ′ may be any appropriate material, including but not limited to a die backside film.
  • a first dielectric layer 152 may be formed on the first microelectronic device 142 , the first protective layer 120 , the first package-on-package pads 128 a , the second package-on-package 128 b , the first secondary device pad 124 a , and the second secondary device pad 124 b .
  • a second dielectric layer 152 ′ may be simultaneously formed on the second microelectronic device 142 ′, the second protective layer 120 ′, the third package-on-package pad 128 a ′, the fourth package-on-package pad 128 b ′, the third secondary device pad 124 a ′, and the fourth secondary device pad 124 b ′.
  • FIG. 8 a first dielectric layer 152 may be formed on the first microelectronic device 142 , the first protective layer 120 , the first package-on-package pads 128 a , the second package-on-package 128 b , the first secondary device pad 124 a , and
  • a plurality of openings 154 may be formed in the first dielectric layer 152 to expose at least a portion of each opening's 154 respective the first microelectronic device contact lands 146 a and 146 b , the first package-on-package pads 128 a , the second package-on-package pads 128 b , the first secondary device pads 124 a , and the second secondary device pads 124 b .
  • a plurality of openings 154 ′ may also be simultaneously formed in the second dielectric layer 152 ′ to expose at least a portion of each opening's 154 ′ respective the second microelectronic device contact lands 146 a ′ and 146 b ′, the third package-on-package pads 128 a ′, the fourth package-on-package pads 128 b ′, the third secondary device pads 124 a ′, and the fourth secondary device pads 124 b ′.
  • the first dielectric layer 152 and the second dielectric layer 152 ′ may comprise silica-filled epoxy, such as build-up films available from Ajinomoto Fine-Techno Co., Inc., 1-2 Suzuki-cho, Kawasaki-ku, Kawasaki-shi, 210-0801, Japan (e.g. Ajinomoto ABF-GX13, Ajinomoto GX92, and the like).
  • the openings 154 and 154 ′ may be formed by any technique known in the art including but not limited to laser or ion drilling, etching, and the like.
  • a conductive material such as copper, aluminum, silver, gold, and alloys thereof, may be disposed within the openings 154 , by any technique known in the art, to form a first microelectronic device contact land first conductive via 166 a , a first microelectronic device contact land second conductive via 166 b , a first package-on-package pad conductive via 162 a , a second package-on-package pad conductive via 162 b , a first secondary device pad conductive via 164 a , and a second secondary device pad conductive via 164 b .
  • the conductive material may also be simultaneously disposed within the openings 154 ′ to form a second microelectronic device contact land first conductive via 166 a ′, a second microelectronic device contact land second conductive via 166 b ′, a third package-on-package pad conductive via 162 a ′, a fourth package-on-package pad conductive via 162 b ′, a third secondary device pad conductive via 164 a ′, and a fourth secondary device pad conductive via 164 b ′.
  • conductive traces may be formed to electrically connect various conductive vias.
  • a first conductive trace 168 a may be formed to electrically connect the first secondary device pad conductive via 164 a and the first microelectronic device contact land first conductive via 166 a and a second conductive trace 168 b may be formed to electrically connect the second secondary device pad conductive via 164 b and the first microelectronic device contact land second conductive via 166 b .
  • a third conductive trace 168 a ′ may be formed to electrically connect the third secondary device pad conductive via 164 a ′ and the second microelectronic device contact land first conductive via 166 a ′ and a fourth conductive trace 168 b ′ may be formed to electrically connect the fourth secondary device pad conductive via 164 b ′ and the second microelectronic device contact land second conductive via 166 b ′.
  • the conductive traces (e.g. elements 168 a , 168 b , 168 a ′, and 168 b ′) may be any appropriate conductive material, including but not limited to copper, aluminum, silver, gold, and alloys thereof.
  • first exterior layer 172 may be formed on the first dielectric layer 152 and a second exterior layer 172 ′ may be formed on the second dielectric layer 152 ′.
  • the exterior layers i.e. first exterior layer 172 and second exterior layer 172 ′ may be used to engineer inherent warpages/stresses in microelectronic packages, as will be understood to those skilled in the art.
  • FIG. 10 illustrates the structure formed on the carrier first surface 108 after depaneling.
  • the first sacrificial material layer 110 may be removed, such as by plasma ashing or solvent release, as will be understood to those skilled in the art.
  • the protective layer 120 may also be removed by any appropriate technique known in the art, as also shown in FIG. 11 .
  • the adhesive layer 144 may be removed from the first microelectronic device 142 , such as by plasma ashing or a dissolution chemical, as shown in FIG. 12 , to form a microelectronic device package 180 . It is understood that if plasma ashing is used to remove the first sacrificial material layer 110 , the adhesive layer 144 may also be removed in a single plasma ashing step.
  • At least one secondary device may then be attached to a secondary device pad.
  • a first secondary device 174 a may be attached to the first secondary device pad 124 a with the metallization layer 122 a
  • a second secondary device 174 b may be attached to the second secondary device pad 124 b with the metallization layer 122 b .
  • the process of FIGS. 1-13 may result in a secondary device (e.g. elements 174 a and 174 b ) which is disposed within a thickness T of the first microelectronic device 142 (i.e. between the first microelectronic device active surface 148 and the first microelectronic device back surface 150 ).
  • FIGS. 14-25 illustrate cross-sectional views of another embodiment of a process of forming a bumpless build-up layer coreless (BBUL-C) microelectronic package with embedded device side secondary devices.
  • a carrier such as the carrier 100 of FIG. 1
  • at least one stand-off may be formed on the carrier.
  • a first stand-off 202 a and a second stand-off 202 b may be formed on the carrier first surface 108
  • a third stand-off 202 a ′, and a fourth stand-off 202 b ′ may be formed on the carrier second surface 108 ′.
  • the stand-offs e.g. elements 202 a , 202 b , 202 a ′, and 202 b ′
  • a first sacrificial material layer 210 such as a photoresist material
  • a second sacrificial material layer 210 ′ such as a photoresist material
  • a first protective layer 220 may be formed on the first sacrificial material layer 210
  • a second protective layer 220 ′ such as a metal foil may be formed on the second sacrificial material layer 210 ′, as shown in FIG.
  • the first sacrificial material layer 210 and the second sacrificial material layer 210 ′ may be formed by any technique known in the art, including but not limited to spin coating, dry photofilm lamination, and chemical vapor deposition.
  • the first protective layer 220 and the second protective layer 220 ′ may be formed by any technique known in the art, including but not limited to deposition and foil lamination.
  • the first sacrificial material layer 210 and the second sacrificial material layer 210 ′ may be deposited to thickness of between about 300 ⁇ m and 600 ⁇ m.
  • an opening 232 may be formed through the first protective layer 220 to expose a portion of the first sacrificial material layer 210
  • an opening 232 ′ may be formed simultaneously in second protective layer 220 ′ to expose a portion of the second sacrificial material layer 210 ′.
  • the first protective layer opening 232 and the second protective layer opening 232 ′ may be formed by any technique known in the art, including but not limited to photolithographic patterning and etching. It is understood that the first sacrificial material layer 210 and the second sacrificial material layer 210 ′ may act as an etch stop during the formation of the first protective layer opening 232 and the second protective layer opening 232 ′.
  • an opening 234 may be formed, using the first protective layer 220 as a mask, through the first sacrificial material layer 210 to expose the first stand-off 202 a , the second stand-off 202 b , and a portion of the carrier first surface 108 .
  • An opening 234 ′ may be formed simultaneously, using the second protective layer as a mask, through the second sacrificial material layer 210 ′ to expose the third stand-off 202 a ′, the fourth stand-off 202 b ′, and a portion of the carrier second surface 108 ′.
  • the first sacrificial material layer opening 234 and the second sacrificial material layer opening 234 ′ may be formed by any technique known in the art, including but not limited to photolithography, wherein the first copper layer 102 and the second copper layer 102 ′ may act as etch stops.
  • package-on-package (PoP) pads may be formed on the protective layers (e.g. elements 220 and 220 ′).
  • FIG. 19 illustrates a first package-on-package pad 228 a and a second package-on-package pad 228 b formed on the first protective layer 220 , and a third package-on-package pad 228 a ′ and a fourth package-on-package pad 228 b ′ formed on the second protective layer 220 ′.
  • Metallization layers i.e. elements 226 a , 226 b , 226 a ′, and 226 b ′ may be disposed between their respective protective layers (e.g.
  • the package-on-package pads may be used to form connections between microelectronic device packages in the z-direction for stacking (e.g. referred to as 3D stacking), without the need for through silicon vias.
  • the package-on-package pads may be formed by any technique known in the art, including deposition, photolithographic patterning, and etching.
  • a first microelectronic device 242 may be attached by a back surface 250 thereof with an adhesive material 244 to the carrier first surface 108 within the first sacrificial material layer opening 234 .
  • the first microelectronic device 242 may have at least one contact land (shown as elements 246 a and 246 b ) on an active surface 248 thereof.
  • a second microelectronic device 242 ′ may be attached by a back surface 250 ′ with an adhesive material 244 ′ to the carrier second surface 108 ′ within the second sacrificial material layer opening 234 ′.
  • the second microelectronic device 242 ′ may have at least one contact land (shown as elements 246 a ′ and 246 b ′) on an active surface 248 ′ thereof.
  • the first microelectronic device 242 and the second microelectronic device 242 ′ may be any desired device, including but not limited to a microprocessor (single or multi-core), a memory device, a chipset, a graphics device, an application specific integrated circuit, or the like.
  • the adhesive material 244 and 244 ′ may be any appropriate material, including but not limited to a die backside film.
  • At least one secondary device may then be attached to a respective stand-off.
  • a first secondary device 274 a may be attached to the first stand-off 202 a with an adhesive material 276 a
  • a second secondary device 274 b may be attached to the second stand-off 202 b with an adhesive material 276 b
  • a third secondary device 274 a ′ may be attached to the third stand-off 202 a ′ with an adhesive material 276 a ′
  • a fourth secondary device 274 b ′ may be attached to the fourth stand-off 202 b ′ with an adhesive material 276 b′.
  • a first dielectric layer 252 may be formed on the first microelectronic device 242 , the first protective layer 220 , the first package-on-package pads 228 a , the second package-on-package pads 228 b , the first secondary device 274 a , and the second secondary device 274 b .
  • a second dielectric layer 252 ′ may be simultaneously formed on the second microelectronic device 242 ′, the second protective layer 220 ′, the third package-on-package pad 228 a ′, the fourth package-on-package pad 228 b ′, the third secondary device 274 a ′, and the fourth secondary device 274 b ′.
  • FIG. 22 a first dielectric layer 252 may be formed on the first microelectronic device 242 , the first protective layer 220 , the first package-on-package pads 228 a , the second package-on-package pads 228 b , the first secondary device 274 a , and
  • a plurality of openings 254 may be formed in the first dielectric layer 252 to expose at least a portion of each opening's 254 respective the first microelectronic device contact lands 246 a and 246 b , the first package-on-package pad 228 a , the second package-on-package pad 228 b , the first secondary device 274 a , and the second secondary device 274 b .
  • a plurality of openings 254 ′ may be simultaneously formed in the second dielectric layer 252 ′ to expose at least a portion of each opening's 254 ′ respective the second microelectronic device contact lands 246 a ′ and 246 b ′, the third package-on-package pad 228 a ′, the fourth package-on-package pad 228 b ′, the third secondary device 274 a ′, and the fourth secondary device 274 b ′.
  • the first dielectric layer 252 and the second dielectric layer 252 ′ may comprise silica-filled epoxy.
  • the openings 254 and 254 ′ may be formed by any technique known in the art including but not limited to laser drilling, ion drilling, etching, and the like.
  • a conductive material may be disposed within the first dielectric layer openings 254 (see FIG. 22 ), by any technique known in the art, to form a first microelectronic device contact land first conductive via 266 a , a first microelectronic device contact land second conductive via 266 b , a first package-on-package pad conductive via 262 a , a second package-on-package pad conductive via 262 b , a first secondary device first conductive via 264 1 a , a first secondary device second conductive via 264 2 a , a second secondary device first conductive via 264 1 b , and a second secondary device second conductive via 264 2 b .
  • the conductive material may also be simultaneously disposed within the second dielectric layer openings 254 ′ to form a second microelectronic device contact land first conductive via 266 a ′, a second microelectronic device contact land second conductive via 266 b ′, a third package-on-package pad conductive via 262 a ′, a fourth package-on-package pad conductive via 262 b ′, a third secondary device first conductive via 264 1 a ′, a third secondary device second conductive via 264 2 a ′, a fourth secondary device first conductive via 264 1 b ′, and a fourth secondary device second conductive via 264 2 b ′.
  • a second microelectronic device contact land first conductive via 266 a ′ As further shown in FIG.
  • conductive traces may be formed to electrically connect various conductive vias.
  • a first conductive trace 268 a may be formed to electrically connect at least one of the first secondary device first conductive via 264 1 a and the first secondary device second conductive via 264 2 a , and the first microelectronic device contact land first conductive via 266 a .
  • a second conductive trace 268 b may be formed to electrically connect at least one of the second secondary device first conductive via 264 1 b and the second secondary device second conductive via 264 2 b , and the first microelectronic device contact land second conductive via 266 b .
  • a third conductive trace 268 a ′ may be formed to electrically connect at least one of the third secondary device first conductive via 264 1 a ′ and the third secondary device second conductive via 264 2 a ′, and the second microelectronic device contact land first conductive via 266 a ′.
  • a fourth conductive trace 268 b ′ may be formed to electrically connect at least one of the fourth secondary device first conductive via 264 1 b ′ and the fourth secondary device second conductive via 264 2 b ′, and the second microelectronic device contact land second conductive via 266 b ′.
  • the conductive traces (e.g. elements 268 a , 268 b , 268 a ′, and 268 b ′) may be any appropriate conductive material.
  • first exterior layer 272 may be formed on the first dielectric layer 252 and a second exterior layer 272 ′ may be formed on the second dielectric layer 252 ′.
  • the exterior layers i.e. first exterior layer 272 and second exterior layer 272 ′ may be used to engineer inherent warpages/stresses in microelectronic packages, as will be understood to those skilled in the art.
  • FIG. 24 illustrates the structure formed on the carrier first surface 108 after depaneling, wherein the stand-offs 202 a and 202 b (see FIG. 23 ) may be removed by any appropriate technique known in the art. It is understood that if the stand-offs 202 a and 202 b are copper as is the carrier layers, the stand-offs 202 a and 202 b may be removed during the depaneling process. As shown in the FIG. 25 , the first sacrificial material layer 210 (see FIG.
  • first microelectronic device adhesive layer 244 and the secondary device adhesive layers 276 a and 276 b may also be removed from the first microelectronic device 242 , such as by plasma ashing or a dissolution chemical, as also shown in FIG. 25 , to form a microelectronic device package 280 . It is understood that if plasma ashing is used to remove the first sacrificial material layer 210 , the first microelectronic device adhesive layer 244 may also be removed in a single step.
  • the process of FIGS. 14-25 may result in a secondary device (e.g. elements 274 a and 274 b ) which is disposed within a thickness T of the first microelectronic device 242 (i.e. between the first microelectronic device active surface 148 and the first microelectronic device back surface 250 ).
  • a secondary device e.g. elements 274 a and 274 b
  • the secondary devices i.e. elements 274 a , 274 b , 274 a ′, and 274 b ′ (see FIG. 21 )
  • the same opening i.e. elements 234 , 234 ′ (see FIG. 18 )
  • the microelectronic devices 244 and 244 ′ see FIG. 21 )
  • Unique openings can be created for the secondary devices and the microelectronic devices separately to allow optimization, such as minimal build-up layer thickness variability or warpage engineering, as will be understood to those skilled in the art.
  • FIGS. 26-38 illustrate cross-sectional views of another embodiment of a process of forming a bumpless build-up layer coreless (BBUL-C) microelectronic package with embedded device-side secondary devices.
  • a carrier such as the carrier 100 of FIG. 1 , may be provided, wherein a first stand-off material layer 302 may be deposited over the carrier first surface 108 and a second stand-off material layer 302 ′ may be simultaneously deposited over the carrier second surface 108 ′.
  • the first stand-off material layer 302 and the second stand-off material layer 302 ′ may be formed of any appropriate material, including but not limited to a photoresist material, and formed by any technique known in the art, including but not limited to spin coating, dry photofilm lamination, and chemical vapor deposition. In one embodiment, the first stand-off material layer 302 and the second stand-off material layer 302 ′ may be deposited to thickness of between about 30 ⁇ m and 100 ⁇ m.
  • an opening 304 may be formed through the first stand-off material layer 302 to expose a portion of the carrier first surface 108
  • an opening 304 ′ may be formed simultaneously in second stand-off material layer 302 ′ to expose a portion of the carrier second surface 108 ′.
  • the first stand-off material layer opening 304 and the second stand-off material layer opening 304 ′ may be formed by any technique known in the art, including but not limited to photolithographic patterning and developing.
  • the photoresist material when a photoresist material is used to form the first stand-off material layer 302 and the second stand-off material layer 302 ′, the photoresist material may be flood exposed (e.g. crosslinked) by exposure to radiation (e.g. light), which is shown as arrows 306 and 306 ′, respectively.
  • a first sacrificial material layer 310 such as a photoresist material, may be formed over the first stand-off material layer 302 and in the first stand-off material layer opening 304 (see FIG.
  • a second sacrificial material layer 310 ′ such as a photoresist material, may be formed over the second stand-off material layer 302 ′ and in the second stand-off material layer opening 304 ′ (see FIG. 27 ).
  • the first sacrificial material layer 310 and the second sacrificial material layer 310 ′ may be formed by any technique known in the art, including but not limited to spin coating, dry photofilm lamination, and chemical vapor deposition. In one embodiment, the first sacrificial material layer 310 and the second sacrificial material layer 310 ′ may be deposited to thickness of between about 300 ⁇ m and 600 ⁇ m.
  • an opening 332 may be formed through the first sacrificial material layer 310 to expose a portion of the first stand-off material layer 310 and a portion of the carrier first surface 108
  • an opening 332 ′ may be formed simultaneously in the second sacrificial material layer 310 ′ to expose a portion of the second sacrificial material layer 310 ′ and a portion of the carrier second surface 108 ′.
  • the first sacrificial material layer opening 332 and the second sacrificial material layer opening 332 ′ may be formed by any technique known in the art, including but not limited to photolithographic patterning and developing.
  • first stand-off material layer 302 and second stand-off material layer 302 ′ may result in the first stand-off material layer 302 and second stand-off material layer 302 ′ being substantially unaffected during the formation of the first sacrificial material layer opening 332 and the second sacrificial material layer opening 332 ′.
  • a first microelectronic device 342 may be attached by a back surface 350 thereof with an adhesive material 344 to the carrier first surface 108 within the first sacrificial material layer opening 332 .
  • the first microelectronic device 342 may have at least one contact land (shown as elements 346 a and 346 b ) on an active surface 348 thereof.
  • a second microelectronic device 342 ′ may be attached by a back surface 350 ′ with an adhesive material 344 ′ to the carrier second surface 108 ′ within the second sacrificial material layer opening 332 ′.
  • the second microelectronic device 342 ′ may have at least one contact land (shown as elements 346 a ′ and 346 b ′) on an active surface 348 ′ thereof.
  • the microelectronic devices may be any desired devices, including but not limited to a microprocessor (single or multi-core), a memory device, a chipset, a graphics device, an application specific integrated circuit, or the like.
  • At least one secondary device may then be attached to a respective stand-off material.
  • a first secondary device 374 a may be attached to the first stand-off material layer 302 with an adhesive material 376 a
  • a second secondary device 374 b may be attached to the first stand-off material layer 302 with an adhesive material 376 b
  • a third secondary device 374 a ′ may be attached to the second stand-off material layer 302 ′ with an adhesive material 376 a ′
  • a fourth secondary device 374 b ′ may be attached to the second stand-off material layer 302 b ′ with an adhesive material 376 b′.
  • a first dielectric layer 352 may be formed on the first microelectronic device 342 , the first secondary device 374 a , and the second secondary device 374 b .
  • a second dielectric layer 352 ′ may be simultaneously formed on the second microelectronic device 342 ′, the third secondary device 374 a ′, and the fourth secondary device 374 b .
  • a plurality of openings 354 may be formed in the first dielectric layer 352 to expose at least a portion of each opening's 354 respective the microelectronic device contact lands 346 a and 346 b , the first secondary device 374 a , and the second secondary device 374 b .
  • a plurality of openings 354 ′ may be formed in the second dielectric layer 352 ′ to expose at least a portion of each opening's 354 ′ respective microelectronic device contact lands 346 a ′ and 346 b ′, third secondary device 374 a ′, or fourth secondary device 374 b ′.
  • the first dielectric layer 352 and the second dielectric layer 352 ′ may comprise silica-filled epoxy.
  • the openings 354 and 354 ′ may be formed by any technique known in the art including but not limited to laser drilling, ion drilling, etching, and the like.
  • a conductive material may be disposed within the first dielectric material layer openings 354 (see FIG. 32 ), by any technique known in the art, to form a first microelectronic device contact land first conductive via 366 a , a first microelectronic device contact land second conductive via 366 b , a first secondary device first conductive via 364 1 a , a first secondary device second conductive via 364 2 a , a second secondary device first conductive via 364 1 b and a second secondary device second conductive via 364 2 b .
  • the conductive material may also be simultaneously disposed within the second dielectric material layer openings 354 ′ (see FIG.
  • conductive traces may be formed to electrically connect various conductive vias.
  • a first conductive trace 368 a may be formed to electrically connect at least one of the first secondary device first conductive via 364 1 a and the first secondary device second conductive via 364 2 a , and the first microelectronic device contact land first conductive via 366 a .
  • a second conductive trace 368 b may be formed to electrically connect at least one of the second secondary device first conductive via 364 1 b and the second secondary device second conductive via 364 2 b , and the first microelectronic device contact land second conductive via 366 b .
  • a third conductive trace 368 a ′ may be formed to electrically connect at least one of the third secondary device first conductive via 364 1 a ′ and the third secondary device second conductive via 364 2 a ′, and the second microelectronic device contact land first conductive via 366 a ′.
  • a fourth conductive trace 368 b ′ may be formed to electrically connect at least one of the fourth secondary device first conductive via 364 1 b ′ and the fourth secondary device second conductive via 364 2 b ′, and the second microelectronic device contact land second conductive via 366 b ′.
  • the conductive traces (e.g. elements 368 a , 368 b , 368 a ′, and 368 b ′) may be any appropriate conductive material.
  • first exterior layer 372 may be formed on the first dielectric layer 352 and a second exterior layer 372 ′ may be formed on the second dielectric layer 352 ′.
  • the exterior layers i.e. first exterior layer 372 and second exterior layer 372 ′ may be used to engineer inherent warpages/stresses in microelectronic packages, as will be understood to those skilled in the art.
  • FIG. 34 illustrates the structure formed on the carrier first surface 108 after depaneling.
  • the first stand-off material layer 302 and the first sacrificial material layer 310 may be removed, such as by a solvent release.
  • the first microelectronic device adhesive material layer 344 , the first secondary device adhesive material 376 a , and the second secondary device adhesive material 376 b may then be removed, such as by plasma ashing, as shown in FIG. 36 , to form a microelectronic device package 380 .
  • a controlled plasma ashing could be used to simultaneously remove the first stand-off material layer 302 , the first sacrificial material layer 310 , the first microelectronic device adhesive material layer 344 , the first secondary device adhesive material 376 a , and the second secondary device adhesive material 376 b . It is further understood that a controlled plasma ashing could be used to remove the first stand-off material layer 302 , the first microelectronic device adhesive material layer 344 , the first secondary device adhesive material 376 a , and the second secondary device adhesive material 376 b , while leaving the first sacrificial material layer 310 in place, as shown in FIG. 37 , to form a microelectronic device package 390 .
  • the process of FIGS. 26-37 may result in a secondary device (e.g. elements 374 a and 374 b ) which is disposed within a thickness T of the first microelectronic device 342 (i.e. between the first microelectronic device active surface 348 and the first microelectronic device back surface 350 ).
  • a secondary device e.g. elements 374 a and 374 b
  • FIGS. 28-37 show in stand-off layer being formed for a microelectronic device package, it is understood that multiple stand-off material layers could be formed and various pockets or cavities could be formed within the materials to allow for the creation of various package architectures for microelectronic device and package stacking and also multi-device embedding, as will be understood to those skilled in the art.
  • the subject matter of the present description is not necessarily limited to specific applications illustrated in FIGS. 1-37 .
  • the subject matter may be applied to other microelectronic device packaging applications.
  • the subject matter may also be used in any appropriate application outside of the microelectronic device fabrication field.
  • the subject matter of the present description may be a part of a larger bumpless build-up package, it may include multiple stacked microelectronic dice, it may be formed at a wafer level, or any number of appropriate variations, as will be understood to those skilled in the art.

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US13/169,162 US8937382B2 (en) 2011-06-27 2011-06-27 Secondary device integration into coreless microelectronic device packages
TW101119764A TWI489917B (zh) 2011-06-27 2012-06-01 將二次裝置整合入無芯微電子裝置封裝組件中之技術
JP2014517243A JP5866441B2 (ja) 2011-06-27 2012-06-25 コアレスマイクロエレクトロニクスデバイスパッケージへの第2デバイスの集積
CN201280032156.7A CN103620767B (zh) 2011-06-27 2012-06-25 微电子器件封装及其形成方法
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DE112012002654.3T DE112012002654B4 (de) 2011-06-27 2012-06-25 Integration sekundärer Bauelemente in kernlose mikroelektronische Bauelement-Packages
PCT/US2012/043945 WO2013003257A2 (en) 2011-06-27 2012-06-25 Secondary device integration into coreless microelectronic device packages
SG2013084900A SG194999A1 (en) 2011-06-27 2012-06-25 Secondary device integration into coreless microelectronic device packages
DE112012007316.9T DE112012007316B3 (de) 2011-06-27 2012-06-25 Integration sekundärer bauelemente in kernlose mikroelektronische bauelement-packages
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TW201330726A (zh) 2013-07-16
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WO2013003257A3 (en) 2013-03-07
SG194999A1 (en) 2013-12-30
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GB2505802B (en) 2016-01-06
DE112012002654T5 (de) 2014-04-17
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US20150135526A1 (en) 2015-05-21
GB2505802A (en) 2014-03-12
WO2013003257A2 (en) 2013-01-03
CN103620767B (zh) 2016-11-09
JP5866441B2 (ja) 2016-02-17
US20120326271A1 (en) 2012-12-27
TWI489917B (zh) 2015-06-21
US9686870B2 (en) 2017-06-20

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